Programmable logic valve control with PROFIBUS type PLVC 2

Transcription

1 Programmable logic valve control with PROFIBUS type PLVC 2 See also other electronic valve controller/accessory: Type PLVC 4 acc. to D Type PLVC-CAN acc. to D 7845 Z Type CAN-HMI acc. to D 7845 HMI 1. General information The programmable logic valve control of type PLVC 2 consists of a complex PLC-enabled micro-control unit with integrated amplifiers for mobile and stationary hydraulic applications. The wide range of possible application includes, among others: o Hydraulic clamping systems for machine tools o Presses o PROFIBUS/CAN-Bus gateway o Hoisting equipment The various control tasks are realized through: o Modular system with extension and supplementary modules - Basic module - Extension module (additional inputs/outputs, CAN-Bus) - Small display for diagnosis and parameterization (via CAN-Bus) - Large display for diagnosis and parameterization (via CAN-Bus) - CAN-Bus controlled power relay o Flexible programmability according to IEC standard (PLC-programming via instruction list (IL), function block diagram (FBD) or structured text (ST)) o Various interfaces (RS232, PROFIBUS), CAN-Bus (optional) o Free parameterization of all outputs as well as complete diagnosis capability and short-circuit protection o Remote diagnosis via modem or mobile phone o Combination of multiple PLVC s via CAN-Bus within one integrated unit for the control of complex systems o Conversion from PROFIBUS to CAN-Bus and vice versa. The main performance parameters include furthermore: o Basic module PLVC 2-4 analog inputs (for joysticks, potentiometers, sensors such as analog pressure sensors) - 5 digital inputs (for limit switches, pressure switches, push buttons etc.) - 3 frequency inputs (for rotary sensors, speed sensors, incremental encoder etc.) - Emergency-Stop (opto-decoupled) - Interface for RS232 and PROFIBUS - 4 outputs for prop. or ON/OFF valves (current-controlled, high side) 2 A - 8 digital outputs for resistant or inductive loads 1.2 A - Power supply V DC, max. 5 A o Extension module PLVC 2 - EW - 8 analog / digital inputs - 8 digital outputs for resistant or inductive loads 1.2 A - 4 relay outputs (optional, possible with changed layout that omits 4 digital outputs), change-over contact, rating 1.7 A - CAN-Bus - Power supply V DC, max. 5 A Attention: Emergency stop of the basic module does not apply to the digital outputs of the extension! o Functional software features - PLC programming via IL or ST - Parameterization during operation - PROFIBUS and optional CAN-Bus are integrated in the firmware 2003 by HAWE Hydraulik HAWE Hydraulik SE STREITFELDSTR MÜNCHEN D Programmable logic valve control May

2 D page 2 2. Available Versions 2.1 Basic module Order examples: PLVC 2 - G - OS/EN Basic module PLVC 2 - X - EW - OS/DE Basic module with extension module PLVC 2 - G /VVVV - OS/EN PLVC 2 - X /AAJJ - EW /VVVVVVVV - OS/DE Basic module Firmware: OS/DE - German OS/EN - English Analog inputs: V V DC J V DC A ma Optional extension module, see sect. 2.2 Note on the specification of analog inputs: All analog inputs are delivered with the default assignment V DC (coding V). Differing specification can be specified in the coding, e.g. coding A = ma or coding J = V DC. General data Casing, protection class IP 20 (IEC 60529) Temperature range Power supply Max. total current Required external fusing Protection -40 C to +80 C 10 V DC to 30 V DC 10 A (basic module) 10 A (slow blow) Reverse polarity protection Load dump protection (DIN 40839) Shock proof (vibration: IEC , shock: IEC ) EMV (EN , EN , EN , EN ) Monitoring Cable connections Micro-controller Basic parameter memory Short-circuit, under-voltage, and over-voltage Cable break By means of via spring-cage connectors Phoenix for up to 1.5 mm 2 diameter 80C167, 16 bit EEPROM 256 words Memory Flash: 256 kbytes RAM: 128 kbytes Mounting Casing material Mass (weight) Phoenix clip type casing for clip-rails Plastic; cover in light alloy (anodized) approx. 0.3 kg (basic module) approx. 0.1 kg (extension module)

3 D page 3 Power specifications of connections (Block diagram basic module, see page 4) Connector rail Function Description Parameter - Power supply Rated voltage U N V DC Max. total current (power) 10 A - Proportional and/or I min ma ON/OFF outputs 0-3 I max ma (with high-side measuring) Dither frequency Hz Dither amplitude (in relation to PWM) % Cold resistance Ohm X 1 X 2 - Frequency input 0-2 Limit frequency f lim = 5 khz - Digital inputs 0-4 Voltage range V DC / 5 kohm individually switchable debouncing for increasing/decreasing signal flank - Digital outputs 0-7 for ON/OFF-valves and consumers with V DC / 1.2 A resistance characteristics - Emergency-Stop input opto-decoupled - Interface RS232 Interface parameter 19.2 kbaud - Analog interface bit A DC & 1024 steps ma (for joysticks, potentiometers, V DC (default) sensors, etc.) V DC Range monitoring - Interface PROFIBUS DP-Slave max. 6 MBaud 2.2 Extension module PLVC 2 - EW General data Power supply 10 to 30 V DC Max. total current 10 A Required external fusing 10 A (slow blow) Mounting Installed into the basic system Power specifications of connections Connector rail Function Description Parameter X 1 - Power supply Rated voltage U N V DC max. total current (power) 10 A X 3-8 analog inputs 10 bit A DC & 1024 steps ma V DC (default) V DC X 5 - Digital outputs 8-15 for ON/OFF-valves and consumers V DC / 1.2 A with resistance characteristics X 6 - CAN-Bus interface 100, 125, 250, 500 kbaud

4 D page 4 Block diagram (basic and extension module) Ubat: VDC Protected against: Reverse polarity Load- Dump Over/under voltage Power supply internal 5 VDC +/- 15 VDC 5 V CAN, PROFIBUS Emergency-Stop (opto-decoupled) Emergency-Stop logic 4 analog and 8 digital Inputs Monitoring: Cable break, short-circuit and range X 1 nominal, actual X 1 Controller: 80C167CR Flash: 256 kbytes RAM: 128 kbytes EEPROM: 256 words 4x PWM out, 2.2 A high side Monitoring: Cable break, short-circuit and range X 2 X 6 8 digital or analog Inputs Range monitoring 8 x digital Out, 1.2 A short-circuit protected X 5 X 3 Optional extension: 8 x digital Out, 1.2 A short-circuit protected

5 D page 5 3. Software, Programming, Diagnosis 3.1 Software Scope of delivery includes the following software package as standard: o Firmware ( C -programmed real-time operation system) with integrated PROFIBUS und CAN-Bus functionality as well as PLC-capability o Functionality of prop. amplifiers o Initializing functions for all inputs and outputs o Diagnosis software Available as additional options: o Diagnosis for CAN-Bus (incl. continuous chart logger) o Function module, adapted for specified applications (on request) Examples: - Max. load control - Synchronicity / Positioning - Flow control (e.g. via prop. flow control valves type SE and SEH acc. to D 7557/1) - Pressure control (e.g. via prop. pressure limiting valves type PMV acc. to D 7485/1 and electrical pressure transducer type DT 11 acc. to D 5440 T/2 and / or type DT 2 acc. to D 5440 T/1) 3.2 Configuration software PLVC Visual tool a) Standard version The Windows based software PLVC Visual tool (availably free of charge) for configuration and supervision of controller type PLVC. This software provides the following functionality: o Supervision and configuration of all in- and outputs of the control o Generation of projects for each control o Freely selectable nomenclature of all in- and outputs o Export of the layout in various formats (PDF, Excel) o Loading and saving of program and parameters o Transfer of a new firmware o Update via Internet o etc. b) Extended version In addition to the standard version of this software there is also an extended version available (not free of charge). This versions contains an integrated oscilloscope. The oscilloscope has the following functionality: o Monitoring of up to 20 signals (in- and outputs as well as internal variable values from the running control program) o storage period up to 24 h o Graphics/scope export of the stored files as Bitmap, JPEG, GIF, Postscript, PDF, PCX, SVG o Export of the indiv. values as text, HTML, XML or Excel o Import of saved data o Automatic scaling o Legend either displayed or masked o Displayed statistics o etc. 3.3 Programming environment OpenPCS The controller type PLVC can be freely programmed conforming IEC (best with structured text (ST)). Basically, the customer can program his control himself. The software OpenPCS, available from HAWE Hydraulik, is required for programming. Additional to the user interface there are also manufacturer specific function blocs e.g. controls for prop. outputs, input of frequencies available from HAWE Hydraulik. Additional HAWE Hydraulik offers customer oriented programming tutorials. 3.4 Diagnosis The following output equipment can be used for diagnosis: o PC - connected to interface CAN-Bus or RS232, for parameterization, programming, error detection as well as remote diagnosis via modem. o CAN-HMI display (see D 7845 HMI), connected via CAN-Bus, for error detection and adjustment parameterization o VT-software, this software tool enables the diagnosis and parameterization of the PLVC (see sec. 3.2).

6 D page Function blocks General: The manufacturer-specific function blocks serve to indicate to the PLC-programmer the interfaces to the actual system. They are structured into the following two groups. Group 1: Initializing functions (INI-functions) These functions are used for parameterization and/or configuration of the inputs and outputs - normally only once at start-up. It is also possible to apply this parameterization through the firmware. All these parameters and configurations are included in the system s EEPROM. Thus they are preset and can be overwritten by the PLC-system. The terminal program (scope of delivery), allows to check, change and save (EPROM and/or file) all settings. Due to these configurations and parameterizations all data is available at runtime in an already converted and standardized form, which even can include a ramp or debouncing information. This makes it possible to write the data directly onto the outputs without conversion and supplemented with ramp information and/or other time-related information. Group 2: Functions that are normally invoked cyclically during runtime (runtime module) These functions are used to read input data, logically link them and to write them onto the outputs. The documentation of the existing function blocks is included in the software package of the PLVC. 4. Dimensions of basic and extension module

7 D page 7 5. Safety and installation notes General information Liability The scope of delivery for the programmable logic valve control type PLVC includes an firmware and - on special agreement - a customized software. It is the duty of the customer to test the requested functionality of the PLVC as he is responsible for the faultless operation and final application of the PLVC. Attention: Whenever a PLVC is replaced it is additionally necessary to order the current version of the software including the operation parameter by the manufacturer of the machine. The customer is responsible to take care that the requested functionality and safety of the application program is fulfilled. When local laws make an approval by a notified body (testing or approval organization) necessary the customer has to apply for it. This description is integral part of the device. It contains information regarding the correct use of the PLVC and must be read prior to installation or prior to use. Make sure to follow the instructions of this description. Failure to comply with the notes or any operation that falls outside the intended usage, wrong installation or faulty handling can cause serious impairment of the safety of people and machinery and as such will prejudice any liability and warranty claims. This instruction is written for personnel, who can be considered to be technically knowledgeable in the understanding of the EMC-guideline 89/336 EEC and the low-voltage guideline 73/23 EEC. The controller must be installed and made operational by a professional electrician (programmer and/or service technician). 5.1 During installation Electrical connection, grounding, arrangement of the wiring: o Connect housing with GND (electrical interference protection), select shortest connection between casing and machine (independent of negative terminal and voltage supply) o Wiring in accordance with safe protective low voltage and/or electrically separated from other electric circuits o Faulty switching can trigger unintended signals at the outputs of the control device. Attention: The parallel switching of external voltage sources (e.g. emergency activation via push button) and the outputs of the PLVC is not permitted! o Pay attention to application-relevant documents (circuit diagrams, software descriptions, etc.). o Recommended cross sections of the connection lines Power supply, relays: >= 1 mm² Other inputs and outputs: >= 0.5 mm² o Only use shielded signal lines o Do not install any wiring for electronic systems close to other power-fed lines in the machine. o Make sure to use only additional accessory approved by HAWE Hydraulik SE o A safety switch must be installed to interrupt the power supply of the electronic system to deactivate system in case of emergencies. This safety switch must be installed within easy reach for the operator. If the safety switch is activated the machine must be brought into standstill in a safe status. The system s design must guarantee this feature. Installation conditions o It must not be mounted nearby heat generating components or sub-assemblies. o It must not be placed near-by to radio facilities. o An emergency cut-off has to be provided. This emergency cut-off has to be positioned at the machinery in such a manner that it is easily accessible by the operator. It has to be made sure by the manufacturer of the machinery that it can achieve a save position after the emergency cut-off is activated. o The control lines must nor be routed nearby power supply lines. o Line disruption and short-cut detection for the control lines have to be provided. o The power supply lines (+ and -) for controller and extensions has to be split-up as close to the controller as possible, see illustrations below. Correct: Extension 2 Extension 1 Basic control unit Wrong: Extension 2 Extension 1 Basic control unit o All terminals for the power supply of the controller type PLVC have to be connected always o All signal lines should be shielded o Take care that sensors connected are properly grounded.

8 D page Installation, operation and maintenance o Make sure to stay within the temperature range for operations between -40 C to +80 C o Surfaces may encounter higher temperatures o Do not install in the vicinity of machine parts and modules that develop great heat (e.g. exhaust) o Prior to any welding work to be done on the machine (the vehicle), all PLVC devices must be disconnected from the power supply (positive and negative terminal) and/or a potential separation must be guaranteed o Make sure to keep sufficient distance to radio-engineering installations. Notes on proportional and switching solenoids and other switched inductive consumers: o Make sure to test the PLVC s correct function only with connected proportional solenoids o Make sure to connect all other switched inductive consumers, which are not connected to the PLVC, close to inductivity with spark arrester diodes. Contact tech_support@hawe.de in case of doubt or in case of malfunctioning. 5.3 Loading of the firmware Each controller type PLVC comes with the current version of the firmware. It can be updated via Windows based computer (PC/Laptop) according to customer specifications or with additional functionality Firmware is working A new firmware can be installed over the operative one. All functionality needed for such an upload is integrated in the current firmware. Connect the controller type PLVC and PC via the serial interface and start the respective upload program of the firmware Firmware is not working A new firmware can even be installed, when the apparent firmware won t start-up (e.g. after discontinued upload of an firmware). Procedure o Connect controller and PC via the serial interface. o Cut-off the controller o Short-cut the two pins, accessible via the cutout (see pict. below), with a conducting tool e.g. a small screw- driver. o Switch-on the controller, while both pins are short-cut. The LEDs on the side must be off. o Start download of the firmware Cutout of the housing:

9 D page Mechanical installation Mounting For dimensions, see sect. 4, Mounting with clip type housing for clip-rails Co. PHOENIX No wire end sleeves should be used when connecting the individual lines to the terminal rail of the PLVC. Best tear-out resistance is achieved, when the line end (insulation removed) is inserted into the spring-cage. This way the spring will bend the line end for additional strength - slightly tear at the line to ensure proper installation. The pictures below show the proper working sequence.

10 D page Components of the control system Communication a) Serial interface The basic PLVC 2 features one serial interface. It is positioned at terminal rail X1, Pin 34, 35, and 36. Functionality via the serial interface: o Monitoring current signals from the PLVC o Setting adjustment for prop. outputs and analog inputs o Creation of measurement plots (oscilloscope of the Visual Tool) The PLVC is connected via a standard serial 9-pin interface line and the respective adapter to the PC. The adapter can easily be self-made. Take a 9-pin D-sub-socket, solder Pin 2 to RX, 3 to TX and 5 to GND. These lines are connected later to terminal rail X1. The transfer rate can be set between 9600 and kbaud. Adapter for serial interface Terminals at basic PLVC 2 X X X Pin of D-sub-socket b) CAN-Bus CAN-bus (Controller Area Network) is a asynchrone, serial bus system, where only two lines are required. Twisted-Pair-lines with a wave resistance of Ohm are recommended acc. to ISO (High-Speed Medium Access Unit). The max. (theoretical) line length is e.g.. 40 m for 1 Mbit/s, 100 m for 500 kbit/s or 500 m for 125 kbit/s. The extension of PLVC features a CAN port, where additional controller type PLVC or sensors (industrial standard CanOpen) may be connected. The CAN-bus interface supports protocols CanOpen and J1939. CAN-Bus baud rate The transfer rate via CAN-bus can be set to following rates: o 50 kbaud o 75 kbaud o 100 kbaud o 125 kbaud o 250 kbaud o 500 kbaud o 1000 kbaud CAN-bus termination Two terminal resistors of 120 Ohm (between CAN_HIGH and CAN_LOW) must be positioned at the lead ends of the bus lines and there only. These terminal resistors are integrated at the PLVC. They can be activated when there is a connection between X6.2 (CAN low) and X6.1, in case the PLVC is the final unit of a CAN-network. c) PROFIBUS PLVC 2 features a PROFIBUS interface, enabling data exchange with a superordinated PLC control. The transfer rate is max. 6 MBit/s. PLVC 2 will adjust automatically to the respective transfer rate. A GSD-file must be available. A PROFIBUS-CAN-Bus gateway can be generated via the optional extensions of the PLVC Outputs a) Proportional solenoids o Other consumers switched-on and off, which are not connected to the PLVC must be provided with clamp diodes nearby the source of inductivity Proportional outputs PLVC provides current controlled PWM-outputs, i.e. the set current is maintained via return current measurement no matter whether the resistance of the coil fluctuates due to temperature changes. PWM frequency is 1 khz. The pulse ratio can be set between 10% and 94%. Both, dither frequency (on and off frequency) and dither amplitude can be adjusted as well.

11 D page Inputs a) Emergency-stop input There is an emergency-stop input at terminal X1.23 of the basic PLVC, which has to be fed with V to ensure that the valve ports are energized. It is standard set-up of the controller, that the controller has to be rebooted after the emergency-stop had been activated. The PLVC has to be switched-off and subsequently switched-on after the emergency actuation had been actuated. This behavior can be changed by resetting a parameter, that the controller will activate the valves immediately after the emergency stop port is energized again. b) Analog sensors All kind of sensors, which generate a output signal of 0-5 V, 0-10 V or 4-20 ma, can be connected to the PLVC. The respective configuration of the analog inputs at the PLVC have to be specified in your order. The power supply for analog sensors has to be properly grounded i.e. all via the PLVC, otherwise the sensor signal will be influenced. The power supply for the machinery must not drop below the power supply specification of the sensor 12 V DC systems are prone for this. All lines should be shielded twisted pair cables. The different configurations of the analog inputs have the following input impedances: Input type Impedance 0-5 V 1 MOhm 0-10 V 94 kohm 4-20 ma 220 Ohm Ground connection for the sensors WRONG: + connected at the PLVC, but - is connected to the battery directly CORRECT: + and - are directly connected at the PLVC. Wrong ground connection for the sensor Voltage drop Sensor signal Comparison between 0-10 V and 4-20 ma Basically, sensors with an output signal of 0-10 V or 4-20 ma can be used. Both kind of sensors offer various pro s and con s, see table below. Signal Advantage Disadvantage 0-10 V Measurement in parallel is possible More prone to failure Three lines necessary 4-20 ma Failure resistant Generated voltage drop Integrated line disruption detection Correct input resistors are necessary Two lines necessary c) Joy-sticks Usually joy-sticks generate a signal even in zero position (e.g. 2.5 V for supply voltage 5 V). This has to be taken in account when setting the parameters. Otherwise there may be undesired movement at the machinery, even when the joy-stick is in zero position. d) Speed sensor The basic PLVC unit offers three digital inputs, which can be employed for frequency measurements. The measurable critical frequency is 5 khz. The signal level must be < 0.8 V (OFF) and > 2.5 V (ON). e) Digital input signals The switching threshold of the digital inputs is 10 V and 0.8 V.

12 D page Failure remedy The table below lists failure states and shows possible ways for failure remedy. The use of software of VT of HAWE is mandatory: Failure Reason Remedy Controller won t boot No power supply Check power supply and fuses (LEDs are OFF) Firmware not completely copied Reload firmware Line disruption at the input line Replace line No Login available Controller are OFF Switch-on controller Serial interface is wrongly or not connected Firmware not completely copied Check connection of the serial interface Reload firmware Program does not run Program was stopped via user parameter User parameter 99 must not be set at 4711 Program not completely copied The program name must be visible on the first page after log in via the terminal program Input signal (digital/analog) Line is not connected Connect line is not recognized No signal on the line Check signal strength with a multimeter Valve output without function Line is not connected Connect line Output is not actuated Start via the Terminal Program / Visual Tool and check (failure message OPN = Open) CAN communication disrupted Wrongly adjusted baud rate Check baud rate and readjust if necessary. All controller must be set on the same baud rate Interference via other lines Use shielded lines. Do not route nearby power supply lines.

13 D page Circuitry plan 7.1 Basic controller PLVC 2-G GND - Prop. valve 0 - Prop. valve 1 - GND - Prop. valve 2 - Prop. valve 3 - GND Analog input 0 - Analog input 1 - Analog input 2 - Analog input 3 - GND - Digital output 0 - Digital output 1 - Digital output 2 - Digital output 3 - Digital output 4 - Digital output 5 - Digital output 6 - Digital output 7 - GND - Power supply + - Emergency-Stop input - Digital input 4 - Digital input 6 - Digital input 5 - Digital input 3 - GND - Digital input 7 - Frequency input 0 - Frequency input 1 - Frequency input 2 - GND - RS232 - RS232 - RS232 -